Upper and lower torso garments having an improved band

FIELD OF THE INVENTION

0001The invention relates to circularly knitted upper and lower torso garments, such as a brassiere or brief. More particularly, the present invention relates to a circularly knitted brassiere and a lower torso undergarment having an improved chest band and waist band, respectively, affixed between the overlapping plies of fabric.

BACKGROUND OF THE INVENTION

0002Upper torso garments, such as, brassieres generally and sports bras in particular have a torso encircling band that is knitted at or attached to the lower edge of the brassiere to provide stability and additional support to the wearer. Such bands also are knitted at or attached to the upper edge of lower torse undergarments, such as briefs, to function as a waist band. One known way to form a chest band or waist band is to knit a turned welt during the process of knitting the fabric tube. An alternative method is to stitch an elastomeric band to the bottom edge of the brassiere, or the top edge of the brief, around the entire periphery; this additional step requires additional labor and increases costs. The resulting band tends to be relatively bulky and thick, and, therefore more visible and less comfortable when worn.

SUMMARY OF THE INVENTION

0003An aspect of the present invention is a circularly knitted garment, such as a brassiere or brief, having a thin elastomeric band affixed between overlapping plies of knitted fabric. In one exemplary embodiment, the elastomeric band comprises a thin polyamide film having a modulus (kilograms of holding power) that is greater than can be achieved by conventional elastomeric yarns, such as spandex and Lycra®. The modulus of the plies and film combined may be between about 1.0 kg and 4 kg. As used herein, the term “modulus” refers to the kilograms of recovery force available in the material at a given percentage of stretch. The greater the modulus, the stiffer the material, i.e. the more resistant the material will be to linear stretch. Depending upon the type of elastomeric material, its width and thickness, its modulus may vary widely.

0004Another aspect of the present invention is a method of forming a brassiere or lower torso undergarment having an elastomeric band affixed between the overlapping plies of fabric. The method comprises circularly knitting a body that is symmetrically dimensioned for forming a two-ply garment, comprising inner and outer layers when folded about a central fold line. The elastomeric band is positioned proximate the fold line and the plies are symmetrically overlapped about the fold line, thus enclosing the elastomeric band and forming the two-ply garment with a torso band that is thinner and, therefore, less visible and more comfortable when worn. In one embodiment, the elastomeric band is affixed to one or both of the inner and outer layers of knitted fabric by the application of temperature and pressure for a selected amount of time.

BRIEF DESCRIPTION OF THE DRAWINGS

0005The present invention will be more apparent from the following detailed explanation of embodiments of the invention in connection with the accompanying drawings.

0006<figref idref="DRAWINGS">FIG. 1</figref> is a front perspective environmental view of the brassiere of the present invention.

0007<figref idref="DRAWINGS">FIG. 2</figref> is a rear perspective environmental view of the brassiere of <figref idref="DRAWINGS">FIG. 1</figref>, illustrating an embodiment having a rear closure.

0008<figref idref="DRAWINGS">FIG. 3</figref> is a rear perspective environmental view of the brassiere of <figref idref="DRAWINGS">FIG. 1</figref>, illustrating a sports-type bra embodiment without a rear closure.

0009<figref idref="DRAWINGS">FIG. 4</figref> is a front view of the brassiere of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>.

0010<figref idref="DRAWINGS">FIG. 5</figref> is a rear view of the brassiere of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>.

0011<figref idref="DRAWINGS">FIG. 6</figref> is a cross-sectional view of the brassiere of <figref idref="DRAWINGS">FIG. 1</figref>, taken along Line <b>6</b>-<b>6</b>.

0012<figref idref="DRAWINGS">FIG. 7</figref> is a front perspective environmental view of boxer briefs of the present invention.

0013<figref idref="DRAWINGS">FIG. 8</figref> is a cross-sectional view of the briefs of <figref idref="DRAWINGS">FIG. 7</figref>, taken along line <b>8</b>-<b>8</b>.

DETAILED DESCRIPTION

0014One aspect of the present invention is directed to an upper torso garment, such as, a brassiere, a sports bra or a camisole. Referring to <figref idref="DRAWINGS">FIGS. 1-6</figref> in general, a circularly-knitted brassiere is shown generally as <b>100</b>. The circularly-knitted brassiere <b>100</b>, which is formed on a conventional circular knitting machine, may comprise a two-ply brassiere body having overlapping inner <b>112</b> and outer <b>114</b> layers, or plies. While a two-ply brassiere is illustrated and described herein, the invention is not limited to a two-ply garment; rather, one-ply garments, such as brassieres and lower torso undergarments, are within the scope of the invention.

0015The brassiere body may be formed of any of the conventional materials such as polyester, nylon, etc. The body may be formed by also knitting in one or more elastomeric yarns, such as spandex, having some degree of elasticity for securing the garment about the wearer's torso. Each ply of fabric for the embodiments described herein may be between about 0.6 mm and about 2.0 mm thick.

0016As shown in <figref idref="DRAWINGS">FIGS. 2</figref>, <b>4</b> and <b>5</b>, the brassiere disclosed herein comprises a pair of breast cups <b>120</b>, and a torso encircling strap <b>130</b> extending outwardly from the outer edges of each breast cup <b>120</b>, with the two torso straps <b>130</b> fastening at the back of the wearer with fasteners <b>150</b>. In the exemplary embodiment shown in <figref idref="DRAWINGS">FIG. 3</figref>, a single continuous torso strap <b>135</b> extends between the outer edges of the breast cups <b>120</b> to encircle the torso of the wearer. This embodiment is typical of a pullover sports-type brassiere. Further, the breast cups <b>120</b> may be either molded after the brassiere body is formed, or may be knitted in as loose areas on the front of the body during the knitting process.

0017As shown in <figref idref="DRAWINGS">FIGS. 1-6</figref>, an elastomeric band <b>170</b> is inserted along the bottom of the brassiere <b>100</b>, between the inner <b>112</b> and outer <b>114</b> plies, and extends beneath the breast cups <b>120</b>, the central gore <b>180</b>, and along the lower edges of the torso straps <b>130</b>, <b>135</b>.

0018Turning now to <figref idref="DRAWINGS">FIG. 6</figref>, the elastomeric band <b>170</b> of the brassiere <b>100</b> comprises a relatively thin elastomeric material having an improved modulus and that maintains a relatively consistent modulus across a useful range of elongation. Depending upon the type and style of the brassiere <b>100</b>, the thickness of the elastomeric band <b>170</b> may range from between about 0.010 mm and 0.45 mm to reduce the visibility of the elastomeric material when the garment is worn. The optimal thickness of the elastomeric band <b>170</b> will depend on the desired level of control to be provided for the brassiere <b>100</b>, which is typically size dependent. As will be appreciated, the thinner the elastomeric band <b>170</b>, the less visible the band when worn. The degree of control and support for the brassiere <b>100</b> type and style also depends on the width of the elastomeric band <b>170</b>. The width of the elastomeric band <b>170</b> can range from about one-quarter (¼) inch for a minimally supporting bra up to seven (7) or more inches wide for a lower torso control garment. An optimal width for the exemplary embodiments illustrated herein is between about three-quarters (¾) inch and one and one-quarter (1¼) inches.

0019In one embodiment, the elastomeric band <b>170</b> comprises a thin film of thermoplastic elastomer (TPE). The thermoplastic elastomer may comprise a polyamide blend. One such polyamide blend is available under the trademark Pebax® from Arkema Inc. of King of Prussia, Pa. Other thin elastomeric materials, including other films, having the physical properties described below, may be suitable to form the elastomeric band <b>170</b>.

0020By way of example and comparison, for the exemplary embodiments shown herein, a typical knitted-in torso band, e.g., a turned welt, would be approximately 2.0 mm thick. A cut and sew brassiere with a sewn in elastic band of similar weight to the turned welt would be approximately 1.8 mm thick. A band having the polyamide film would be approximately 1.5 mm thick.

0021The modulus of the elastomeric material depends on its type of material, width and thickness. In the exemplary embodiments described herein, an optimal modulus may be between about 1.0 and 4.0 kilograms. As shown in the several examples in Table 1 below, this range in the modulus corresponds to between about 95% and 140% in deformation (stretch) when the elastomeric band <b>170</b> is subjected to a length direction static load of 7 kilograms.

0022<tables id="TABLE-US-00001" num="00001"><table frame="none" colsep="0" rowsep="0" pgwide="1"><tgroup align="left" colsep="0" rowsep="0" cols="5"><colspec colname="1" colwidth="56pt" align="left" /><colspec colname="2" colwidth="56pt" align="center" /><colspec colname="3" colwidth="56pt" align="center" /><colspec colname="4" colwidth="56pt" align="center" /><colspec colname="5" colwidth="56pt" align="center" /><thead><row><entry namest="1" nameend="5" rowsep="1">TABLE 1</entry></row><row><entry namest="1" nameend="5" align="center" rowsep="1" /></row><row><entry /><entry /><entry>Modulus (kg)</entry><entry>Modulus (kg)</entry><entry>Total Percent</entry></row><row><entry>Elastomeric Band</entry><entry>Thickness of</entry><entry>(40% elongation)</entry><entry>(60% elongation)</entry><entry>Deformation</entry></row><row><entry>Material</entry><entry>Elastomeric Band</entry><entry>(band plus plies)</entry><entry>(band plus plies)</entry><entry>(band plus plies)</entry></row><row><entry namest="1" nameend="5" align="center" rowsep="1" /></row></thead><tbody valign="top"><row><entry>Pebax ®</entry><entry>0.10 mm</entry><entry>1.08</entry><entry>1.66</entry><entry>132%</entry></row><row><entry>Pebax ®</entry><entry>0.15 mm</entry><entry>1.59</entry><entry>2.25</entry><entry>123%</entry></row><row><entry>SBC by Kraton ®</entry><entry>0.30 mm</entry><entry>2.31</entry><entry>3.50</entry><entry>102%</entry></row><row><entry namest="1" nameend="5" align="center" rowsep="1" /></row></tbody></tgroup></table></tables>

0023By way of comparison, the body of brassiere <b>100</b> will have a modulus of less than 1 kilogram. For example, the two overlapped plies, formed from a conventional blend of 89% weight nylon and 11% weight spandex has a modulus of about 0.132 kg at 40% elongation and about 0.35 kg at 60% elongation. As seen in Table 1 above, the elastomeric bands provide a reduced increase in modulus with increased elongation. This produces a brassiere <b>100</b> that will be comfortable over a larger range of sizes. In the torso band region at the bottom of the brassiere proximate the fold line <b>173</b>, the two-ply body material alone would allow for elongation of 160% when tested under the same 7 kg load as the samples in Table 1.

0024Referring again to <figref idref="DRAWINGS">FIG. 6</figref>, the method of forming the brassiere <b>100</b> of the present invention is best illustrated. The brassiere body or blank is knitted in the form of a tube on a conventional circular knitting machine. The center periphery of the tube corresponds to the fold line <b>173</b> about which the inner <b>112</b> and outer <b>114</b> layers will be overlapped into the two-ply brassiere body.

0025The elastomeric band <b>170</b> is positioned proximate the center fold line <b>173</b> on what will become the inner surfaces of the two-ply brassiere body when the tube is folded. The elastomeric band <b>170</b> may be coated on one or both sides with a heat-sealable adhesive <b>172</b> for adhering the elastomeric band <b>170</b> in position once the brassiere construction is complete. One suitable heat-sealable adhesive <b>172</b> is RX 2641, available from Bixby International Corp. of Newburyport, Mass. The invention, however, is not limited to using a heat-sealable adhesive to adhere the band <b>170</b>; rather, the use of other suitable materials and methods for securing the band to the garment are within the scope of the invention.

0026The inner <b>112</b> and outer <b>114</b> layers of the brassiere body are next symmetrically overlapped about the fold line <b>173</b>, enclosing the elastomeric band <b>170</b> and forming the two-ply brassiere body as described above. Where a heat-sealable adhesive <b>172</b> is applied to one or both sides of the elastomeric band <b>170</b>, the elastomeric band <b>170</b> is affixed between the two plies with an air-operated press having upper and lower heating elements. An application temperature may be between about 150 degrees Fahrenheit and 380 degrees Fahrenheit, preferable about 320 degrees Fahrenheit. The application pressure should be no less than about 10 psi and no more than about 120 psi, preferably between about 30 and about 60 psi. The preferred pressure should be applied for no less than about 5 seconds and no more than about 90 seconds, preferably between about 20 and about 30 seconds.

0027Once the elastomeric band <b>170</b> is adhered between the inner <b>112</b> and outer <b>114</b> layers, the brassiere body may be cut to the desired shape. Subsequently, trim <b>190</b> is applied along the free edges, shoulder straps <b>160</b> attached, and fasteners <b>150</b> are affixed to complete the brassiere <b>100</b> construction. Where shoulder strap portions <b>160</b> are formed and cut with the brassiere body, they need only to be seamed together proximate the top of the shoulder. Similarly, where the torso strap <b>135</b> is continuous, no fasteners <b>150</b> are necessary.

0028Another aspect of the present invention is directed to a circularly-knitted lower torso undergarment, such as a boxer, a brief, a boxer brief, panties, pantyhose or shapewear. Referring to <figref idref="DRAWINGS">FIGS. 7 and 8</figref>, a boxer brief is shown generally as <b>200</b>. The circularly-knitted brief <b>200</b>, which is formed on a conventional circular knitting machine, comprises a body formed of any of the conventional materials such as polyester, nylon, etc. The body may be formed by also knitting in one or more elastomeric yarns, such as spandex, having some degree of elasticity for securing the garment about the wearer's lower torso.

0029The briefs <b>200</b> of the present invention comprises a pair of leg openings <b>210</b>, a crotch portion <b>230</b> and a waist opening <b>220</b> surrounded by a waist band <b>250</b> of the present disclosure. The embodiment illustrated includes leg portions <b>240</b> as is typical of boxer style briefs. Conventional briefs, i.e. without leg portions <b>240</b>, for males or females having the waist band <b>250</b> are also within the scope of the invention.

0030As best seen in <figref idref="DRAWINGS">FIG. 8</figref>, an elastomeric band <b>270</b>, as described above, is inserted along the waist opening <b>220</b> of the brief <b>200</b>, between inner <b>212</b> and outer <b>214</b> plies. Both the inner and outer plies <b>212</b>, <b>214</b> are formed as parts of a single tube created by a circular knitting machine. The top portion of the tube is then folded downward along a top fold line <b>273</b> to form the waist band <b>250</b> having two plies, the elastomeric band <b>270</b> disposed adjacent to the fold line <b>273</b> and covered by the two plies. The elastomeric band <b>270</b>, inner ply <b>212</b> and outer ply <b>214</b> may be held in place by adhesive <b>272</b>, set using heat and pressure similar to the method discussed above. Alternate methods of adhering the elastomeric band to the body of the brief <b>200</b> are within the scope of the present invention.

0031It should be understood that the foregoing descriptions and examples are only illustrative of the invention. Various alternatives and modifications thereof can be devised by those skilled in the art without departing from the spirit and scope of the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variations.